Smart Water Tray

ABSTRACT

An apparatus and method of utilizing water level sensors within a water tray of a refrigeration system having: a first float switch to determine when a water tray is full and discontinue supplying of water to the water tray, a second float switch to determine when the water inside the watery tray is ready for expulsion, and releasing remaining water in the water tray, a third float switch to determine when the water tray is empty and initiating a harvest cycle. The apparatus may integrate with a low pressure sensor to receive low pressure sensor input to initiate or delay a harvest cycle. The apparatus may integrate with multiple timer controls to initiate certain actions within the refrigeration system.

FIELD OF THE INVENTION

The present invention relates generally to the field of refrigeration system utilizing float switches within a water reservoir tray to control the refrigeration system.

BACKGROUND

Refrigeration systems, utilize water trays as a means to transfer water to the evaporator for freezing. A typical refrigeration system will sense water level within the water tray by means of manual tank floats or utilizing timers to control the inlet water valve to continue to distribute water into the water tray. The refrigeration system transfers the water in the water tray into the evaporator by the assistance of a water pump integrated into the refrigeration system. As the water cycles up into the evaporator, the amount of water in the water tray will be reduced and the inlet water valve will be re-initiated to permit more water to enter the water tray to maintain fullness of the water tray. As a result of this, the refrigeration system water tray is always full with water.

As the water is re-circulated within the refrigeration system certain impurities are collected within the water and only pure water, water free of impurities, can be frozen. As a measure to defend against having a water tray filled with a mixture of pure and impure water, the refrigeration system will introduce cleaning cycles whereby the water tray water is discharged as a means to maintain only pure water within the refrigeration system to increase efficiency of the refrigeration system. As a result of the inefficient manual floats or timers to control the inflow of water into the water tray and the introduction of cleaning cycle to fend off impure water, the water tray discharges more water than necessary during the cleaning cycles resulting in higher water and power usage which is costly for refrigeration system owners and operators.

SUMMARY

A need therefore exists for efficient water supply sensors within a water tray to integrate with or bypass timer controls to reduce the amount of water discharged unnecessarily by the refrigeration system.

The present disclosure articulates the integration of three specific float switches within a refrigeration system water tray to facilitate the control of the refrigeration system. The first float switch is designed to control the flow of water into the water tray. The second float switch is designed to control the action of discharging of water from the water tray. The third float switch is designed to control the action of initiating an ice harvest (or release of ice from the refrigeration system).

In one inventive aspect, a water level sensor control apparatus. In apparatus includes, a water tray, wherein the water tray may be a sloped water tray and used as a reservoir to maintain water supply for the evaporator. The apparatus also includes, a first float switch configured to determine when a first water level has been reached within the water tray, and send a first signal to an inlet valve to discontinue supplying of water to the water tray. The first float switch may further be configured to transmit a harvest delay timer signal to a harvest valve timer with a predetermined harvest valve delay time limit. The first float switch may be further configured to transmit a dump valve delay signal to a dump valve timer with a predetermined dump valve delay time limit. The first float, the second float, and the third float may be configured within at least one reed switch. The apparatus also includes, a second float switch configured to determine when a second water level has been reached within the water tray, and send a second signal to a dump valve to discharge water not yet frozen within the water tray. The apparatus further includes, a third float switch configured to determine when a third water level has been reached within the water tray, and sends a third signal to a harvest valve to initiate a harvest cycle. The third float switch may be further configured to bypass the delay time limit configured within the harvest valve timer. The third float switch may further be configured to bypass the delay time limit configured within the dump valve timer.

In another aspect of the invention, a water level sensor control apparatus. The apparatus includes a water tray, wherein the water tray may be a sloped water tray and used as a reservoir to maintain water supply for the evaporator. The apparatus includes a first float switch configured to send a close inlet valve signal to an inlet valve to discontinue supplying of water to the water tray if a first water level has been reached within the water tray. Alternatively, the first float switch configured to send an open inlet valve signal to an inlet valve to begin supplying of water to the water tray if a first water level has not been reached within the water tray. The apparatus also includes, a low pressure sensor configured to receive a low pressure signal from an evaporator and transmit an intermediate close inlet valve signal to an inlet valve to discontinue supplying of water to the water tray until a harvest cycle is completed within the refrigeration system. The apparatus further includes a second float switch configured to determine when a second water level has been reached within the water tray and send a second signal to a dump valve to discharge water not yet frozen within the water tray. The apparatus further includes a third float switch configured to determine when a third water level has been reached within the water tray and send a third signal to a harvest valve to initiate a harvest cycle. The apparatus further includes, a harvest valve timer configured to maintain a safety time limit for which the refrigeration system must initiate the harvest cycle. The third float switch may be further configured to bypass the safety time limit configured within the harvest valve timer. The apparatus further includes, a hold timer configured to determine if a signal received from the first float switch is a consistent signal for a predetermined time period prior to initiating an open inlet valve signal to discontinue the flow of water to the water tray. The hold timer may be bypassed if the first float switch transmits an overflow signal indicating the inflow of water to the water tray has exceeded the first water level. The first float switch, the second float switch, and the third float switch may be configured within at least one reed switch.

In yet another inventive aspect, a water level sensor control method. The method including supplying water to a water tray from an inlet valve, determining that a first water level has been reached by means of a first float switch, sending a first signal from the first float switch to the inlet valve to discontinue water to the water tray. The method further includes, determining that a second water level has been reached by means of a second float switch, sending a second single from the second float switch to a dump valve to discharge water in the water tray. The method further comprising, determining that a third water level has been reached by means of a third float switch, sending a signal from the third float switch to the harvest valve to release ice from the refrigeration system. The method also includes, determining that a low pressure level has been reached by means of a low pressure sensor, sending a low pressure signal from the low pressure sensor to an inlet valve to temporarily discontinue the inflow of water to the water tray. The method includes determining that a low pressure level has been reached by means of a low pressure sensor, sending a harvest time limit signal from the low pressure sensor to a harvest valve timer to maintain a fixed time period for which the harvest valve must release the ice from the refrigeration system. The third float switch may act as a means to bypass the harvest time limit maintained within the harvest valve timer. The first float, the second float, and the third float may be configured within at least one reed switch. Determining that a first water level has been reached by means of a first float switch may adopt the integration of a hold timer to determine if the signal received from the first float switch may be maintained for a fixed time period.

Neither this summary nor the following detailed description purports to define the invention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of various inventive features will now be described with reference to the following drawings. Throughout the drawings, reference numbers may be re-used to indicate correspondence between referenced elements. The drawings are provided to illustrate example embodiments described herein and are not intended to limit the scope of disclosure.

FIG. 1A illustrates a rear-view of a refrigeration system in accordance to one embodiment.

FIG. 1B illustrates a front-view of a refrigeration system in accordance to one embodiment.

FIG. 1C illustrates a water level sensor control apparatus having three separate switches in accordance to one embodiment.

FIG. 2A illustrates a float switch apparatus in accordance to one embodiment.

FIG. 2B illustrates an internal float switch configuration in accordance with one embodiment.

FIG. 3 illustrates a float switch apparatus installed within a water tray in accordance to one embodiment.

FIG. 4 illustrates a water level sensor control apparatus having three switches within one reed in accordance to one embodiment.

FIG. 5A illustrates a water level sensor control apparatus having a first double and second single float switches in accordance to one embodiment.

FIG. 5B illustrates a water level sensor control apparatus having a first single and second double float switches in accordance to one embodiment.

FIG. 6A illustrates a water level sensor control apparatus having a first single and second single float switches in accordance to one embodiment.

FIG. 6B illustrates a water level sensor control apparatus having a first and second double float switch in accordance to one embodiment.

FIG. 7A illustrates a water level sensor control apparatus having a second single and third single float switches in accordance to one embodiment.

FIG. 7B illustrates a water level sensor control apparatus having a second and third double float switch in accordance to one embodiment.

FIG. 8 illustrates a water level sensor control apparatus comprising three stage sensors in accordance to one embodiment.

FIG. 9 illustrates a water level sensor control apparatus with integrated timer controls in accordance to one embodiment.

FIG. 10 illustrates a water level sensor control apparatus with integrated timer and signal consistency controls in accordance to one embodiment.

DETAILED DESCRIPTION

Specific embodiments will now be described with reference to the drawings. These embodiments are intended to illustrate and, not limit, the present disclosure.

FIG. 1A is an illustrative embodiment of a refrigeration system. In one embodiment of the disclosure, a refrigeration system 210 designed specifically for ice freezing and harvesting. The refrigeration system 210 comprising a plurality of components, including an evaporator 202, a water tray 102, a water pump 206, a water inlet valve 104, a dump valve 106, and a harvest valve 204, an drain opening 208. In one exemplary embodiment of the disclosure, water flows into the water tray 102 through a water inlet valve 104 and is pumped by the water pump 206 up into the evaporator 202 to freeze the water into ice. As the refrigeration system 210 continues to operate and prior to the harvest cycle, the central control unit 840 configured to control the refrigeration system 210 will send a signal that it's ready to harvest, it will then discontinue the flow of water from the water tray 102 up into the evaporator 202 by shutting off the water pump 206 and opening the dump valve 106 to release the water into the drain 208. In one embodiment, the central control unit 840 may be a microcontroller. Thereafter, the refrigeration system 210 central control unit will send a second signal to release thaw gas through a harvest valve (not shown) to allow for the evaporator 202 to release the ice contained within.

FIG. 1B is an illustrative embodiment of a refrigeration system. In one embodiment of the disclosure, a refrigeration system 210 designed specifically for ice freezing and harvesting. The refrigeration system 210 comprising a plurality of components, including a harvest valve 204 to allow for the evaporator 202 to release the ice contained within.

FIG. 1C is an illustrative embodiment of a water level sensor control apparatus. In one embodiment of the disclosure, a water level sensor control apparatus 100 wherein three float switches reside within a water tray 102 which consists of a mixture of water which is distributed to an evaporator for freezing. In one embodiment, the water tray 102 may consist of both pure water 101 and impure water 103, hereafter referred to as water 170, wherein the pure water 101 is water received from the water inlet valve 104 from a pure water supply means (not shown) and the impure water 103 is received from the water inlet valve 104 from a discharge excess water means (not shown) within an evaporator 202 as the water is recycled through a refrigeration system 210. The water tray 102 may be comprised of different configurations and may be a sloped water tray.

In one embodiment, the water inlet means 104 is open, operation and permitting water 170 to flow into the water tray 102 and allowing the water 170 to accumulate due to the accelerated inflow velocity as compared to the velocity of the water 170 leaving the water tray by an outlet means 108 to be destined for the evaporator 202 being pumped by a water pump 206 up into the evaporator 202. For this reason, the water tray 102 will begin to accumulate water 170 and as the water reaches a configurable, predetermined and optimal water supply level it will cause the first float switch 110 (comprised of a first reed 112 and a first float 114) to energize and transmit a signal by means of an electrical wire 105 to a central processing control 840 to cause the closure of the inlet water valve 104.

After the closure of the inlet water valve 104, the refrigeration system 210 will continues to operate and continue to pump water 170 from the water tray 102 to the evaporator 202 by means of a water pump 206. For this reason, as the water 170 reaches a configurable, predetermined, and optimal water discharge level it will cause the second float switch 116 (comprised of a second reed 118 and a second float 120) to energize and transmit a signal by means of an electrical wire 105 to a central processing control 840 to cause the opening of the dump valve 106. The dump valve 106 may be configured to be connected to the water tray 102, the intermediary piping 212 between the water tray 102 and the evaporator 202, or any other physical location configured within the refrigeration system 210.

After the opening of the dump valve 106, the refrigeration system 210 will continue to operate and continue to pump water 170 from the water tray 102 to the evaporator 202 by means of a water pump 206 to allow water to discharge from the dump valve 106. Alternatively, after the opening of the dump valve 106, the refrigeration system 210 will continue to operate, but discontinue the water pump 206 so as to allow water within the refrigeration system 210 to drain from the water tray 102. For this reason, as the water 170 reaches a configurable, predetermined, and optimal water discharge complete level it will cause the third float switch 122 (comprised of a third reed 124 and a third float 126) to energize and transmit a signal by means of an electrical wire 105 to a central processing control 840 to cause the opening of the harvest valve 204. The harvest valve 204 may permit the release of ice stored in the evaporator 202 within the refrigeration system 210 to be discharged and ready for harvesting by operational personal.

FIG. 2A is an illustrative embodiment of a float switch apparatus. In one embodiment, the float switch apparatus 200 may be comprised of at least one wire 105, thread 107, adjustable nut 109, a washer 111, a non-adjustable nut 113, a reed 115, a first lock 172, afloat 119, and a second lock 174. FIG. 2 illustrates an exemplary embodiment of float switch apparatus 200 and its configuration. In one embodiment, the float 119 is contained between a first lock 172 and a second lock 174, wherein the float 119 is configured to adjust upward or downward based upon the floatation of the float 119 within a liquid substance. The floatation of the float 119 upward or downward causes the internal switch configurations to be adjusted as a result. Float switches may be adjusted to properly fit within a water tray and to achieve optimal configuration to measure water levels within a closed container.

FIG. 2B is an illustrative embodiment of internal float switch configuration. In one embodiment, a single reed switch having an internal switch configuration may be comprised of glass tube 121 having inert gas 127, a first reed 123 and a second reed 125 coming together and apart at a contact point 129. The glass tube may be housed within the reed 115 at any location, including: at the top most portions, the lower most portions, the central portion, or anywhere within the reed. In one embodiment, when the first reed 123 and the second reed 125 are repelling, the float switch apparatus 200 is said to be off, or not energized. In one embodiment, when the first reed 123 and the second reed 125 are in contact, the float switch apparatus 200 is said to be on, or energized. Alternative embodiments and opposite configurations than those just described may also exist.

In an alternative embodiment, the float switch apparatus 200 may be comprised of dual reed switch rather than a single reed switch, as just described. In one embodiment, a dual reed switch having an internal switch configuration 191 may be comprised of a glass tube 121 having an inert gas 127, a first NC reed 193, a second NO reed 195 and a third COM reed 197, wherein the reed switch adjusts its contact point 129 between the (COM reed 197 and the NC reed 193) or (COM reed 197 and the NO reed 195). Either of these configurations is possible and the float switch apparatus 200 would be able to operational and fits expectations notwithstanding the underlying switch configuration used.

FIG. 3 is an illustrative embodiment of the float switch apparatus installed within a water tray. In one embodiment, a float switch apparatus 200 installed within a water tray 102 from an upward installation 312 wherein the water level is below water level sensor 302 and the float 119 is not energized as a result. In another embodiment, a float switch apparatus 200 installed within a water tray 102 from an upward installation 312 wherein the water level is at or exceeds water level sensor 304 and the float 119 is energized as a result. In yet another embodiment, a float switch apparatus 200 installed within a water tray 102 from a downward installation 314 wherein the water level is below water level sensor 303 and the float 110 is not energized as a result. In another embodiment, a float switch apparatus 200 installed within a water tray 102 from a downward installation 314 wherein the water level is at or exceeds the water level sensor 304 and the float 119 is energized.

FIG. 4 is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 400 wherein the three separate float switches described and illustrated in FIG. 1B are integrated into a single triple float switch 130 having a reed 115 and a first float 114, a second float 120, and a third float 126. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the water reaches a desired supply level, the first float 114 is energized and the water inlet valve 104 is closed as a result. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray. Finally, as the water 170 in the water tray 102 reaches a lower discharge complete level, then the third float 126 is energized and the harvest valve is opened as a result, releasing the frozen ice within the refrigeration system 210.

FIG. 5A is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 500 wherein the three separate float switches described and illustrated in FIG. 1B are configured within two float switches, a double float switch 132 configured to control the inlet valve 104 and dump valve 106 and a third float switch 122 configured to control the harvest valve 204. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the water reaches a desired supply level, the first float 114 is energized and the water inlet valve is closed as a result. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212. Finally, as the water 170 in the water tray 102 reaches a lower discharge complete level, then the third float float 126 is energized and the harvest valve 204 is opened as a result, releasing the frozen ice within the refrigeration system 210.

FIG. 5B is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 510 wherein the three separate float switches described and illustrated in FIG. 1B are configured within two float switches, a first float switch 110 configured to control the inlet valve 104 and a double float switch 134 configured to control the dump valve 106 and the harvest valve 204. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the water reaches a desired supply level, the first float 114 is energized and the water inlet valve is closed as a result. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212. Finally, as the water 170 in the water tray 102 reaches a lower discharge complete level, then the third float float 126 is energized and the harvest valve 204 is opened as a result, releasing the frozen ice within the refrigeration system 210.

FIG. 6A is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 600 wherein the only two of the three separate float switches described and illustrated in FIG. 1B are configured within two float switches, a first float switch 110 configured to control the inlet valve 104 and a second float switch 116 configured to control the dump valve 106. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the water reaches a desired supply level, the first float 114 is energized and the water inlet valve is closed as a result. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212.

FIG. 6B is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 610 wherein the only two of the three separate float switches described and illustrated in FIG. 1B are configured within a single float switch, a double float switch 132 configured to control the inlet valve and the dump valve 106. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the water reaches a desired supply level, the first float 114 is energized and the water inlet valve is closed as a result. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212.

FIG. 7A is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 700 wherein the only two of the three separate float switches described and illustrated in FIG. 1B are configured, a second float switch 116 configured to control the dump valve 106 and a third float switch 122 configured to control the harvest valve 204. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the harvest control module 808 receives a signal from the refrigeration system 210 that it's ready to initiate harvest, the water inlet valve is closed as a result, and a harvest valve timer 814 may be set. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212. Finally, as the water 170 in the water tray 102 reaches a lower discharge complete level, then the third float 26 is energized and the harvest valve 204 is opened as a result, releasing the frozen ice within the refrigeration system 210.

FIG. 7B is an illustrative embodiment of the water level sensor control apparatus. In one embodiment, a water level sensor control apparatus 710 wherein a double float switch 134 is configured to control the inlet valve 104 and the harvest valve 204. In one embodiment, the water inlet valve 104 permits the inflow of water 170 into a water tray 102 and after the harvest control module 808 receives a signal from the refrigeration system 210 that it's ready to initiate harvest, the water inlet valve 104 is closed as a result, and a harvest valve timer 814 may be set. As the refrigeration system 210 continues to cycle the water 170 to the evaporator 202 through the outlet means 108 and the water level in the water tray 102 is reduced to dump valve supply level, then the second float 120 is energized and the dump valve 106 is opened as a result to discharge water 170 from the water tray or intermediary pipe 212. Finally, as the water 170 in the water tray 102 reaches a lower discharge complete level, then the third float 126 is energized and the harvest valve 204 is opened as a result, releasing the frozen ice within the refrigeration system 210.

FIG. 8 is an illustrative embodiment of water level sensor control apparatus. In one embodiment, the water level sensor control apparatus of comprised of three stages, which will be described in turn.

During the first stage, a water inlet valve 104 is opened and a first float switch 110 is energized when the water level within the water tray reaches a predetermined fill level and sending a first stage signal 801 to a microcontroller (MCU) 802 which subsequently transmits a first stage control signal 807 to a inlet valve control module 804 which controls the opening and closure of the inlet valve 104 (mechanical part). The inlet valve control module 104 will subsequently transmit a close inlet valve signal 809 to the inlet valve 104. The microcontroller (MCU) 802 may be the central processing control for the entire refrigeration system or may be one of multiple microcontrollers installed within the refrigeration system 210. FIG. 8 focuses on the use of a central microcontroller to handle requests coming in from different modules in order to control multiple valves within the refrigeration system 210. In one embodiment, the inlet valve control module 804 may be a hardware control module executing a software program to perform a specific function. Alternatively, the inlet control module 804 may be an entirely software based module executing with integration to the microcontroller (MCU) 802.

During the second stage, a dump valve 106 is closed and a second float switch 116 is energized when the water level within the water tray reaches a predetermined discharge level and sending a second stage signal 803 to a microcontroller (MCU) 802 which subsequently transmits a second stage control signal 811 to a dump valve control module 806 which controls the opening and closure of the dump valve 106 (mechanical part). The dump valve control module 806 will subsequently transmit an open dump valve signal 813 to the dump valve 106. In one embodiment, the dump valve control module 806 may be a hardware control module executing a software program to perform a specific function. Alternatively, the dump valve control module 806 may be an entirely software based module executing with integration to the microcontroller (MCU) 802.

During the third stage, a harvest valve 204 is closed and a third float switch 122 is energized when the water level within the water tray reaches a predetermined discharge complete level and sending a third stage signal 805 to a microcontroller (MCU) 802 which subsequently transmits a third stage control signal 815 to a harvest control module 808 will subsequently transmit an open harvest valve signal 817 to the harvest valve 204 (mechanical part). In one embodiment, the harvest control module 808 may be a hardware control module executing a software program to perform a specific function. Alternatively, the harvest control module 808 may be an entirely software based module executing with integration to the microcontroller (MCU) 802.

In an alternative first stage, an low pressure sensor 810 receiving a signal from an external component sensing a low pressure within the evaporator indicating an initiate ice harvest, sending a low pressure signal 821 to a microcontroller (MCU) 802 which subsequently transmits a first stage control signal 807 to a inlet valve control module 804 which controls the opening and closure of the inlet valve 104 (mechanical part). The inlet valve control module 104 will subsequently transmit a close inlet valve signal 809 to the inlet valve 104. Simultaneously, the microcontroller 802 may transmit a delay harvest signal 816 to inform the harvest control module 808 to wait for a third stage control signal 815 prior to opening the harvest valve 204.

In yet another alternative first stage, an low pressure sensor 810 receiving a signal from an external component sensing a low pressure within the evaporator indicating an initiate ice harvest, sending a low pressure detected signal 819 to a harvest control module 808 which subsequently sends a low pressure signal 821 to a microcontroller (MCU) 802 which subsequently transmits a first stage control signal 807 to an inlet valve control 804 which controls the opening and closure of the inlet valve 104 (mechanical part). The inlet valve control module 104 will subsequently transmit a close inlet valve signal 809 to the inlet valve 104. Simultaneously, delaying the open harvest valve signal until a third stage control signal 815 is received.

FIG. 9 is an illustrative embodiment of water level sensor control apparatus. In one embodiment, the water level sensor control apparatus comprised of three float sensors, an optional dump valve time, and an optional harvest valve timer, which will be described in turn.

In one embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a first stage sensor 831, (2) a second stage sensor 833, (3) a third stage sensor 835, (4) a dump valve timer 812, and (5) a harvest valve timer 814.

In one embodiment, a first stage sensor 831, comprised of a first float switch 110, transmits a first stage signal 801 to a microcontroller (MCU) 802 wherein the micro-controller subsequently transmits three separate signals to (1) an inlet valve control module 804, (2) a dump valve timer 812, and (3) a harvest valve timer 814.

The microcontroller 802 transmits a first stage control signal 807 to an inlet valve control module 804 which analyzes and transmits a close inlet valve signal 809 to close the inlet valve 104.

Simultaneously with the transmission of a first stage control signal 807, the microcontroller 802 may transmit a dump valve time request signal 823 to a dump valve timer 812 which analyzes the request to configure a pre-determined, configurable dump value delay time limit which is stored in memory 837 and transmits a dump valve time response signal 825 to the microcontroller 802 to confirm receipt of dump valve timer request signal 823. The dump valve timer 812 is configured to store a set time value, that when reached, will initiate a second stage control request 811 to open the dump valve 106. However, the dump valve timer 812 configured set time value may be superseded or bypassed if the microcontroller 802 receives a second stage signal 803 from a second stage sensor 833 (comprising a second float switch 116) to open the dump valve 106 prior to the set time value expiration. In one embodiment of the disclosure, the expiration of the dump valve timer 812 set time value will result in dump valve timer expiration signal 841 sent to the microcontroller 802 which subsequently transmits a second stage control signal 811 to the dump valve control module 806 to initiate opening of the dump valve 106.

Simultaneously with the transmission of a first stage control signal 807, the microcontroller 802 may transmit a harvest valve timer request signal 827 to a harvest valve timer 814 which analyzes the request to configure a pre-determined, configurable harvest valve delay timer limit which is stored in memory 839 and transmits a harvest valve time response signal 829 to the microcontroller 802 to confirm receipt of harvest valve timer request signal 827. The harvest valve timer 814 is configured to store a set time value, that when reached, will initiate a third stage control request 815 to open the harvest valve 128. However, the harvest valve timer 814 configured set time value may be superseded or bypassed if the microcontroller 802 receives a third stage signal 805 from a third stage sensor 835 (comprising a third float switch 122) to open the harvest valve 128 prior to the set time value expiration. In one embodiment of the disclosure, the expiration of the harvest valve timer 814 set time value will result in harvest valve timer expiration signal 843 sent to the microcontroller 802 which subsequently transmits a third stage control signal 815 to the harvest control module 808 to initiate opening of the harvest valve 128.

In one embodiment, a second stage sensor 833, comprised of a second float switch 116, transmits a second stage signal 803 to a microcontroller (MCU) 802 wherein the micro-controller subsequently transmits two separate signals to (1) a dump valve control module 805, and (2) a dump valve timer 812.

The microcontroller 802 transmits a second stage control signal 811 to a dump valve control module 806 which analyzes and transmits an open dump valve signal 813 to open the dump valve 106.

The microcontroller 802 transmits a dump valve time bypass signal 845 to a dump valve timer 812 which analyzes the request and automatically resets it's timer to a null value state.

In an alternative embodiment, a second stage sensor 833, comprised of a second float switch 116, transmits a second stage signal 803 to a microcontroller (MC) 802 wherein the micro-controller subsequently transmits a dump valve timer bypass signal 845 to the dump valve timer 812 which analyzes the request and automatically resets it's timer to a null value state and transmits a dump valve timer expiration signal 841 to the microcontroller 802 which will subsequently transmits a second stage control signal 811 to the dump valve control module 806 to initiate opening of the dump valve 106.

In one embodiment, a third stage sensor 835, comprised of a third float switch 122, transmits a third stage signal 805 to a microcontroller (MCU) 802 wherein the micro-controller subsequently transmits two separate signals to (1) a harvest valve control module 808, and (2) a harvest valve timer 814.

The microcontroller 802 transmits a third stage control signal 815 to a harvest valve control module 808 which analyzes and transmits a open harvest valve signal 817 to open the harvest valve 128.

The microcontroller 802 transmits a harvest valve time bypass signal 847 to harvest valve timer 814 which analyzes the request and automatically resets it's timer to a null value state.

In an alternative embodiment, a third stage sensor 835, comprised of a third float switch 122, transmits a third stage signal 805 to a microcontroller (MC) 802 wherein the micro-controller subsequently transmits a harvest valve timer bypass signal 847 to the harvest valve timer 814 which analyzes the request and automatically resets it's timer to a null value state and transmits a harvest valve timer expiration signal 843 to the microcontroller 802 which will subsequently transmits a third stage control signal 815 to the harvest valve control module 808 to initiate opening of the harvest valve 128.

In an alternative embodiment related to a first stage, a first stage sensor 831 is bypassed if an low pressure sensor 810 receiving a signal from an external component sensing a low pressure within the evaporator indicating an initiate ice harvest, sending a low pressure signal 821 to a microcontroller (MCU) 802 which subsequently transmits a first control signal 807 to a inlet valve control module 804 which controls the opening and closure of the inlet valve 104 (mechanical part). The inlet valve control module 104 will subsequently transmit a close inlet valve signal 809 to the inlet valve 104.

Simultaneously with the transmission of a first stage control signal 807, the microcontroller 802 may transmit a dump valve time request signal 823 to a dump valve timer 812 which analyzes the request to configure a pre-determined, configurable dump value delay time limit which is stored in memory 837 and transmits a dump valve time response signal 825 to the microcontroller 802 to confirm receipt of dump valve timer request signal 823. The dump valve timer 812 is configured to store a set time value, that when reached, will initiate a second stage control request 811 to open the dump valve 106. However, the dump valve timer 812 configured set time value may be superseded or bypassed if the microcontroller 802 receives a second stage signal 803 from a second stage sensor 833 (comprising a second float switch 116) to open the dump valve 106 prior to the set time value expiration. In one embodiment of the disclosure, the expiration of the dump valve timer 812 set time value will result in dump valve timer expiration signal 841 sent to the microcontroller 802 which subsequently transmits a second stage control signal 811 to the dump valve control module 806 to initiate opening of the dump valve 106.

In yet another alternative embodiment related to a first stage, a first stage sensor 831 is bypassed if an low pressure sensor 810 receiving a signal from an external component sensing a low pressure within the evaporator indicating an initiate ice harvest, sending a low pressure detected signal 819 to a harvest control module 819 which subsequently sends a low pressure signal 821 to a microcontroller (MCU) 802 which subsequently transmits a first stage control signal 807 to an inlet valve control 804 which controls the opening and closure of the inlet valve 104 (mechanical part). The inlet valve control module 104 will subsequently transmit a close inlet valve signal 809 to the inlet valve 104.

Simultaneously with the transmission of a first stage control signal 807, the microcontroller 802 may transmit a harvest valve timer request signal 827 to a harvest valve timer 814 which analyzes the request to configure a pre-determined, configurable harvest valve delay timer limit which is stored in memory 839 and transmits a harvest valve time response signal 829 to the microcontroller 802 to confirm receipt of harvest valve timer request signal 827. The harvest valve timer 814 is configured to store a set time value, that when reached, will initiate a third stage control request 815 to open the harvest valve 128. However, the harvest valve timer 814 configured set time value may be superseded or bypassed if the microcontroller 802 receives a third stage signal 805 from a third stage sensor 835 (comprising a third float switch 122) to open the harvest valve 128 prior to the set time value expiration. In one embodiment of the disclosure, the expiration of the harvest valve timer 814 set time value will result in harvest valve timer expiration signal 843 sent to the microcontroller 802 which subsequently transmits a third stage control signal 815 to the harvest control module 808 to initiate opening of the harvest valve 128.

In an alternative embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a first stage sensor 831, (2) a second stage sensor 833, (3) a dump valve timer 812, and (4) a harvest valve timer 814, wherein the harvest valve timer 814 is utilized as an alternative to a third stage sensor 835.

In an alternative embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a low pressure sensor 810, (2) a second stage sensor 833, (3) a (optional) dump valve timer 812, and (4) a harvest valve timer 814, wherein the harvest valve timer 814 is utilized as an alternative to a third stage sensor 835.

In an alternative embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a first stage sensor 831, (2) a dump valve timer 812, and (3) a harvest valve timer 814, wherein the dump valve timer 812 is utilized as an alternative to a second stage sensor 833 and the harvest valve timer 814 is utilized as an alternative to a third stage sensor 835.

In an alternative embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a low pressure sensor 810, (2) a dump valve timer 812, and (3) a harvest valve timer 814, wherein he low pressure sensor 810 may be utilized as an alternative to a first stage sensor 831, the dump valve timer 812 may be utilized as an alternative to a second stage sensor 833, and the harvest valve timer 814 is utilized as an alternative to a third stage sensor 835.

FIG. 10 is an illustrative embodiment of water level sensor control apparatus. In one embodiment, the water level sensor control apparatus comprised of three float sensors, a hold timer, and a harvest valve timer, which will be described in turn.

In one embodiment of the disclosure, a water level sensor control apparatus, comprising: (1) a first float switch 110, (2) a second float switch 116, (3) a third float switch 122, (4) a hold timer 816, and (5) a harvest valve timer 814.

In one embodiment, a first float switch 110 configured to transmits a first stage signal 801 to a microcontroller (MCU) 802 wherein the micro-controller transmits a hold timer request signal 851 to a hold timer 816 configured within or as an exterior component of the micro-controller. The hold timer 816 is configured to determine if the first float switch 110 first stage signal 801 is consistently being sent to the MCU 802 for a predetermined length of time continuously. If the first stage signal 801 is not consistent, then the water will continue to flow into the water tray 102, but if the first stage signal 801 is consistent, then the hold timer 816 will send a hold timer response signal 853 to micro-controller confirming the consistency of the signal and the microcontroller 802 send a subsequent first stage control signal 807 to the inlet valve control module 804 to close the inlet valve 104. In an alternative embodiment, if the water 170 in the water tank 102 raises too quickly then the micro-controller 802 may bypass the hold timer 816 and send a first stage control signal 807 to the inlet valve control module 804 to close the inlet valve 104. The inlet valve 104 will remain closed and the water 170 in the water tray 102 will begin to drop because the water 170 will be pumped into the evaporator 202, and when this happens then the first float switch 110 will be de-energized and the micro-controller 802 will know to send a first stage control signal 807 to the inlet valve control 804 which sends a subsequent close inlet valve signal 809 to open the inlet valve 104. This cycle of opening and closing the inlet valve will continue until the micro-controller receives a low pressure signal 821 from a low pressure sensor 810 that the evaporator 202 is ready to initiate a harvest cycle.

In one embodiment, the low pressure sensor 810 sends a low pressure signal 821 to the harvest valve timer 814 by sending a safety limit time request 855 through a micro-controller 802 along with a predetermined time limit for which to delay the harvest cycle within the evaporator 202. The harvest valve timer 814 will send a safety limit time response 857 to the micro-controller 802 confirming receipt of harvest time limit. The low pressure sensor 810 will send another first stage control signal 807 through the micro-controller 802 to the inlet valve control module 804 to temporarily close the inlet valve 104 until the harvest cycle is completed.

When the inlet valve 104 is closed, the water 170 in the water tray 102 will begin to decrease because it's being pressurized into the evaporator 202. As a result of decrease water supply in the water tray 102, the second float switch 116 will be energized and send a second stage signal 803 to the micro-controller 802 informing the micro-controller 802 that the water 170 within the water tray 102 has reached a level wherein only impure water 103 resides and that the dump valve 106 should be opened to discharge such water 170. In response, the micro-controller 802 will send a second stage control signal 811 to the dump valve control module 806 to send a open dump valve signal 813 to the dump valve 106 to discharge water in the water tray.

When the dump valve 106 is opened, pressurized water (previously pumped into the evaporator 202) is returned through an intermediary pipe 212 to be released through the dump valve 106 into a drain 208. When the dump valve 106 is open and the water 170 in the water tray 102 is being discharged, the water supply level in the water tray 102 will reach a third threshold wherein the third float switch 122 will be energized. When the third float switch 122 is energized it sends a third stage signal 805 to the micro-controller 802 wherein the micro-controller 802 sends a subsequent third stage control signal 815 to the harvest control module 808 to send a open harvest valve signal 817 to open the harvest valve 204 to initiate a harvest cycle. The third float switch 122 acts as a harvest valve timer 814 bypass wherein if the third float switch 122 is energized because it detects that the water 170 in the water tray 102 has been discharged by opening the dump valve 106. If for some reason the first float switch 110, the second float switch 116 or the third float switch 122 is not working as expected, then low pressure sensor 810 and the harvest valve timer 814 act as secondary means to detect a harvest cycle and initiate a harvest cycle, respectively. In one embodiment, if the second float switch 116 is non-operational and the dump valve 106 is not opened to discharge water in the water tray, resulting in the third switch 122 not energizing, then the harvest valve timer 814 is used to indicate when to initiate a harvest cycle. In another embodiment, if the third float switch 122 is non-operation then the refrigeration system 210 will initiate a harvest cycle when the harvest valve timer 814 completes its preconfigured time limit. In one embodiment, a light indicator using different flashing codes to de-code maintenance concerns may be used to notify user when bypass harvest valve timer was used to uncover float switch maintenance issues or concerns with either the first, second, or third float switches configured within the water tray.

In an alternative embodiment of the disclosure includes utilizing analog signals rather than digital signals to facilitate the transfer of signals from float switches (sensors) to control different mechanical parts within the refrigeration system, including the inlet water valve 104, dump valve 106 and the harvest valve 124. The analog configured design would facilitate the same functionality and results achieves as the digital design described in the disclosure. Therefore, an analog equivalent design is herein specifically identified as relating to the same subject matter as described in the disclosure.

As will be apparent, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Although this invention has been described in terms of certain preferred embodiments and applications, other embodiments and applications that are apparent to those of ordinary skill in the art, including embodiments which do not provide all of the features and advantages set forth herein, are also within the scope of the invention. Accordingly, the scope of the present disclosure is intended to be defined only by the reference to the below claims. 

1. A water level sensor control apparatus, comprising: a water tray configured to receive water through an inlet valve; a first float switch configured to: determine when an upper water level has been reached within the water tray; send a first signal to the inlet valve to discontinue supplying of water to the water tray; a second float switch to initiate after the completion of the first signal configured to: determine when an intermediate water level has been reached within the water tray; send a second signal to a dump valve to discharge water not yet frozen within the water tray; a third float switch to initiate after the completion of the second signal configured to: determine when a third lower water level has been reached within the water tray; sends a third signal to a harvest valve to initiate an ice harvest cycle.
 2. The apparatus of claim 1, wherein the water tray has a sloped bottom surface.
 3. The apparatus of claim 1, wherein the first float switch is further configured to transmit a harvest delay timer signal to a harvest valve timer with a predetermined harvest valve delay time limit.
 4. The apparatus of claim 3, wherein the third float switch is further configured to override the predetermined harvest valve delay time limit configured within the harvest valve timer.
 5. The apparatus of claim 1, wherein the first float, the second float, and the third float are configured within at least two reed switches.
 6. The apparatus of claim 1, wherein the first float switch is further configured to transmit a dump valve delay signal to a dump valve timer with a predetermined dump valve delay time limit.
 7. The apparatus of claim 6, wherein the third float switch is further configured to bypass the predetermined dump valve delay time limit configured within the dump valve timer.
 8. A water level sensor control apparatus, comprising: a water tray configured to receive water through an inlet valve; a first float switch configured to: send a close inlet valve signal to an inlet valve to discontinue supplying of water to the water tray if an upper water level has been reached within the water tray; or send an open inlet valve signal to the inlet valve to begin supplying of water to the water tray if the upper water level has not been reached within the water tray; an refrigerant low pressure sensor within an industrial grade evaporator configured to: detect a low pressure signal; transmit an intermediate close inlet valve signal to the inlet valve to discontinue supplying of water to the water tray until an ice harvest cycle is completed within the industrial grade evaporator; a second float switch configured to: determine when an intermediate water level has been reached within the water tray; send the second signal to a dump valve to discharge water not yet frozen within the water tray prior to the ice harvest cycle.
 9. The apparatus of claim 8, further comprising a third float switch configured to determine when a lower water level has been reached within the water tray and send a third signal to a harvest valve to initiate a the ice harvest cycle.
 10. The apparatus of claim 9, further comprising a harvest valve timer configured to maintain a safety time limit for which the industrial grade evaporator must initiate the ice harvest cycle.
 11. The apparatus of claim 10, wherein the third float switch is further configured to override the safety time limit configured within the harvest valve timer.
 12. The apparatus of claim 8, further comprising a hold timer configured to determine if a signal received from the first float switch is a consistent signal for a predetermined time period prior to initiating the open inlet valve signal to discontinue the flow of water to the water tray.
 13. The apparatus of claim 12, wherein the hold timer is disregarded if the first float switch transmits an overflow signal indicating the inflow of water to the water tray has exceeded the upper water level.
 14. The apparatus of claim 9, wherein the first float switch, the second float switch, and the third float switch are configured within at three reed switches.
 15. A water level sensor control method, comprising: supplying water to a water tray from an inlet valve; determining that an upper water level has been reached by means of a first float switch, sending a first signal from the first float switch to the inlet valve to discontinue water to the water tray; determining that an intermediate water level has been reached by means of a second float switch, sending a second single from the second float switch to a dump valve to discharge water in the water tray prior to an ice harvest cycle; determining that a lower water level has been reached by means of a third float switch, sending a third signal from the third float switch to a harvest valve to initiate the ice harvest cycle within an evaporator.
 16. The method of claim 15, further comprising determining that a low pressure level has been reached by means of a refrigerant low pressure sensor within the evaporator, sending a low pressure signal from the refrigerant low pressure sensor to an inlet valve to temporarily discontinue the inflow of water to the water tray.
 17. The method of claim 15, further comprising determining that a low pressure level has been reached by means of a refrigerant low pressure sensor within the evaporator, sending a harvest time limit signal from the refrigerant low pressure sensor to a harvest valve timer to maintain a fixed time period for which the harvest valve must initiate the ice harvest cycle.
 18. The method of claim 17, wherein the third float switch acts as a means to override the harvest time limit maintained within the harvest valve timer.
 19. The method of claim 15, wherein the first float, the second float, and the third float are configured within two reed switches.
 20. The method of claim 15, wherein determining that the upper water level has been reached by means of a first float switch requires the integration of a hold timer to determine if the first signal received from the first float switch may be maintained for a fixed time period. 